Can you describe the manufacturing process for ZipShape? I have seen a video of a huge circular saw removing material from a solid to achieve the desired section. Could the process possibly be that wasteful?

Unless you have a use for the slices you remove, it still appears that close to 50% of the original block (MDF?) is waste material. I could imagine the ZipShape as manufacturable component but as it is you are taking two solid blocks, removing almost the equivalent mass of one of them, then joining them to get the desired curve.

Nick

(Dont get me wrong, I love the idea of holding the curve via the variable 'zip' geometry, just saying...)